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Old 11-20-2012, 12:52 PM
jude09 jude09 is offline
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Join Date: Dec 2010
Boat: prostar190
Location: midwest
Posts: 6
1994 Prostar sending unit

My feul gauge always reads 1/2 full. I assume it is the sending unit. Do I need to revome the fuel tank to replace the sending unit. It doesn't seem to have enough head clearance to remove unit.
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Old 11-20-2012, 01:22 PM
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mikeg205 mikeg205 is offline
Join Date: Aug 2011
Boat: 1995 Pro Star 205 5.7 Liter
Location: Plainfield - Joliet, IL
Posts: 17,599
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Yes you have to remove it...you can buy sending units directly from http://www.isspro.com/
...A bad day water skiing still beats a good day at work...1995 Pro Star 205....
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Old 11-20-2012, 01:40 PM
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Double D Double D is online now
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Join Date: Sep 2004
Boat: 1994 Mastercraft, ProStar 205, 350 Indmar with 275 hp
Location: UCLA (Upper Canton, Lower Akron)
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Getting them dialed in is another thing....
If its not a competition ski boat, its always second best.

1994 MasterCraft ProStar 205
275 HP 350 Chevy Indmar
Monster Tower & PerfectPass

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"In my many years I have come to a conclusion that one useless man is a shame, two is a law firm and three or more is a congress." - John Adams
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Old 11-22-2012, 01:04 PM
Jorski Jorski is offline
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Join Date: Jul 2004
Boat: 1993 190 with LT1
Location: Toronto, Canada
Posts: 1,469

If the problem were electrical, you would either read all the way empty or all of the way full all of the time.

I had this exact problem. The float that makes your unit work is in a tube. It has magnets on it that the electrical part of the sending unit reads and then send the information to your guage.

In my case, the foam ball, was sort of swollen from years of immersion. Likely yours is also. It could also be stuck due gum or varnish from the gas. The solution is to remove the unit, take the end cap off of the tube and pull out the foam ball.

Be careful, you don't want to knock the magnets off. I also shaved down the ball to make it move a little more freely inside of the tube.

This is worth a shot. You have to remove the old one anyhow, and it just might save you a couple of $$$$.

PS You can undo the clips at the bottom of the tank that hold it in place at the bottom. If you undo the breather vent hose at one end, you can pivot the other end of the tank around to get at the sending unit. This way you don't have to remove it completely.

Let us know how it turns out.

Last edited by Jorski; 11-22-2012 at 01:08 PM.
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Old 11-23-2012, 01:43 PM
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AZDave AZDave is offline
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Join Date: Dec 2006
Boat: 1993 Stars & Stripes Prostar 190 351 285 hp
Location: sw
Posts: 467
I have gone 7 years with out it, but then I don't have my back seat in place so I can check it easily.
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Old 11-23-2012, 05:10 PM
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ricford ricford is offline
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Join Date: Feb 2011
Boat: 1996 Prostar190
Location: Muskoka, Canada
Posts: 605
Fixed mine myself last year. I had to epoxy the magnets back into the foam float. I found some 2 part epoxy that was gas resistant at the local marina, but some guys have used super glue. Easy fix, there is a thread on it in the frequently asked questions section.
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